Composite cloth sheet for decoration

ABSTRACT

The present invention relates to a composite cloth sheet for decoration comprising a thin film layer on the upper surface of a cloth layer, in whiche a first hot melt film layer is formed between the cloth layer and the thin film layer and a second hot melt film layer is formed at the lower surface of the cloth layer so as to allow the first hot melt film layer and the second hot melt film layer to be fused through holes of the cloth layer, thereby preventing shrinkage even at a high temperature of 250° C. or higher, and implementing an appropriate level of flexibility while improving the adhesive force of a material to be adhered and the cloth layer, or the cloth layer and the thin film layer.

TECHNICAL FIELD

The present invention relates to a composite fabric sheet for ornamentation, and more particularly, to a composite fabric sheet for ornamentation, in which hot melt film layers are formed on both the top surface and the underside of a base fabric layer in such a manner that a first hot melt film layer is formed between the base fabric layer and a thin film layer and a second hot melt film layer is further formed on the base fabric layer and an adherend substrate so as to allow the first hot melt film layer and the second hot melt film layer to be fused together by means of through-holes of the base fabric layer.

BACKGROUND ART

In general, items such as shoes, bags, wallets, or various pouches are products having a sense of style that chases the fashion trend of the times. Such an item is configured such that a variety of parts or ornaments are attached to a main body made of a fabric such as cloth or synthetic resin by means of sewing or bonding.

For example, a process of manufacturing shoes among the above-mentioned products will be described hereinafter with reference to FIG. 1.

As shown in FIG. 1, a typical shoe is manufactured by a process in which a vamp 3 and a back stay 2 are attached and sewn on an outer surface of a base fabric 1 for the upper of a shoe, a fore stay 4 is attached and sewn on the outer surface of the vamp 3, a toe cap 5 is attached and sewn on the vamp 3 and the fore stay 4, and an ornament 6 of various shapes is finally bonded to the outer surface of the toe cap 5 using an adhesive. The products such as bags or wallets are also manufactured in a process similar to the manufacturing process of the shoes.

However, the attachment and sewing method used in the conventional shoe manufacturing process entails a problem in that a complex pattern of sewing lines are formed on the upper portion of the shoe through a complicated sewing step, so that if a user wears his or her shoes for a long period of time, soil, dust or the like is caught either in the sewing lines or between the gaps of the sewing lines, which allows the sewing lines to get discolored into black color ones, and thus causes damage to an expensive shoes, thereby reducing fashionability of the product. In addition, the conventional shoe manufacturing process entails a problem in that the shoes is subjected to a number of sewing steps, and thus a defective rate of shoes by the sewing lines is very high, thereby deteriorating productivity.

Thus, recently, footwear companies such as Nike and the like have been actively conducting researches on a technology in which a base or foundation fabric for ornamentation is attached to an adherend substrate such as the upper of a shoe using a no-sewing method.

Meanwhile, in regard to the attachment technology of the no-sewing method, there has been currently proposed a technology in which a hot melt film made of a synthetic resin such as polyurethane or the like is laminated on the underside of a base fabric layer formed with patterns and a thin film layer is laminated on the top surface of the base fabric layer to prepare a composite fabric sheet for ornamentation, and then the prepared composite fabric sheet is attached to an adherend substrate such as the upper of a shoe so that various designs for the patterns of the base fabric layer can be implemented and the coating effect of the thin film layer on the patterns of the base fabric layer can realized, thereby preventing the patterns of the base fabric layer from being peeled off.

However, such a conventional attachment technology encounters a problem in that if the hot melt film layer is formed only on the underside of the base fabric layer, shrinkage or contraction occurs at a high temperature of more than 250° C. during the manufacture of the adherend substrate such as the upper of the shoe, resulting in formation of unspecified wrinkles on the adherend substrate such as the upper of the shoe.

Furthermore, there is caused a problem in that since the hot melt film layer is formed only on the underside of the base fabric layer to allow an adhesive force to become weak, the adherend substrate and the base fabric layer or the base fabric layer and the thin film layer are easily peeled off.

Moreover, the hot melt film layer is formed only on the underside of the base fabric layer so that when the base fabric layer is cut out, a thread and the like come loose out of a cut cross-section of the base fabric layer, which makes it impossible to commercialize.

DISCLOSURE OF INVENTION Technical Problem

Accordingly, the present invention has been made in order to solve the above-described problems occurring in the prior art, and it is an object of the present invention is to provide a composite fabric sheet for ornamentation, in which hot melt film layers are formed on both the top surface and the underside of a base fabric layer in such a manner that a first hot melt film layer is formed between the base fabric layer and a thin film layer and a second hot melt film layer is further formed on the base fabric layer and an adherend substrate so as to allow the first hot melt film layer and the second hot melt film layer to be fused together by means of through-holes of the base fabric layer, thereby preventing shrinkage even at a high temperature of more than 250° C., and implementing an appropriate level of flexibility while improving the adhesive force of either the adherend substrate and the base fabric layer, or the base fabric layer and the thin film layer.

Another object of the present invention is to provide a composite fabric sheet for ornamentation, in which the first hot melt film layer and the second hot melt film layer are fused together by means of the through-holes of the base fabric layer, so that a thread and the like is prevented from coming loose out of a cut cross-section of the base fabric layer even though the base fabric layer is cut out.

Still another object of the present invention is to provide a composite fabric sheet for ornamentation, in which the coating effect of the thin film layer on the patterns of the base fabric layer is implemented, so that the peeling off and the like of the patterns can be prevented and products can be upgraded by highlighting the beauty of design.

Technical Solution

To achieve the above objects, the present invention provides a composite fabric sheet for ornamentation, which includes a thin film layer formed on the top surface of a base fabric layer, the composite fabric sheet including: a first hot melt film layer formed between the base fabric layer and the thin film layer; and a second hot melt film layer formed on the underside of the base fabric layer.

Preferably, the base fabric layer may be composed of a mesh material.

Further, preferably, the thin film layer may have a thickness of 200-300 μm, the first hot melt film layer may have a thickness of 30-50 μm, and the second hot melt film layer may have a thickness of 200-300 μm.

Advantageous Effects

The composite fabric sheet for ornamentation of the present invention has the following advantageous effects.

The hot melt film layers are formed on both the top surface and the underside of a base fabric layer in such a manner that a first hot melt film layer is formed between the base fabric layer and a thin film layer and a second hot melt film layer is further formed on the base fabric layer and an adherend substrate so as to allow the first hot melt film layer and the second hot melt film layer to be fused together by means of through-holes of the base fabric layer, thereby preventing shrinkage even at a high temperature of more than 250° C., and implementing an appropriate level of flexibility while improving the adhesive force of either the adherend substrate and the base fabric layer, or the base fabric layer and the thin film layer.

In addition, the first hot melt film layer and the second hot melt film layer are fused together by means of the through-holes of the base fabric layer, so that a thread and the like is prevented from coming loose out of a cut cross-section of the base fabric layer even though the base fabric layer is cut out.

Besides, the coating effect of the thin film layer on the patterns of the base fabric layer is implemented, so that the peeling off and the like of the patterns can be prevented and products can be upgraded by highlighting the beauty of design.

BRIEF DESCRIPTION OF THE DRAWINGS

The above as well as the other objects, features and advantages of the present invention will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a diagrammatic view illustrating an outer appearance of a general shoe;

FIG. 2 is a cross-sectional view illustrating the configuration of a composite fabric sheet for ornamentation according to an embodiment of the present invention;

FIG. 3 is a cross-sectional view illustrating a process in which a first hot melt film layer and a second hot melt film layer of FIG. 2 are fused together;

FIG. 4 is a real photograph illustrating a result of a flexibility test for the composite fabric sheet for ornamentation of FIGS. 2; and

FIG. 5 is a real photograph illustrating a result of a bonding test for the composite fabric sheet for ornamentation of FIG. 2.

BEST MODE FOR CARRYING OUT THE INVENTION

The present invention for achieving the above-mentioned objects is directed to a composite fabric sheet for ornamentation. In the meantime, in the detailed description and the accompanying drawings, illustration and explanation on the construction and operation which a person skilled in the art can easily understand will be briefly made or will be omitted to avoid redundancy. In particular, illustration and explanation on the detailed technical construction and operation of elements, which have no direct connection with the technical features of the present invention, will be omitted, and only the technical constructions directly related with the present invention will be briefly illustrated and explained.

FIG. 2 is a cross-sectional view illustrating the configuration of a composite fabric sheet for ornamentation according to an embodiment of the present invention, and FIG. 3 is a cross-sectional view illustrating a process in which a first hot melt film layer and a second hot melt film layer of FIG. 2 are fused together.

As shown in FIG. 2, a composite fabric sheet 100 for ornamentation according to the present invention includes a thin film layer 20 formed on the top surface of a base fabric layer 10. The composite fabric sheet further includes: a first hot melt film layer 10 a formed between the base fabric layer 10 and the thin film layer 20; and a second hot melt film layer 10 b formed on the underside of the base fabric layer 10. For this reason, as shown in FIG. 3, the first hot melt film layer 10 a and the second hot melt film layer 10 b are fused together by means of through-holes H of the base fabric layer 10.

In other words, the present invention allows the first hot melt film layer 10 a and the second hot melt film layer 10 b respectively formed on the top surface and the underside of the base fabric layer 10 to be fused together by means of the through-holes H of the base fabric layer 10, so that shrinkage can be prevented even at a high temperature of more than 250° C., and the adhesive force of either an adherend substrate and the base fabric layer 10, or the base fabric layer 10 and the thin film layer 20 is improved to prevent ether the adherend substrate and the base fabric layer 10, or the base fabric layer 10 and the thin film layer 20 from being peeled off from each other, thereby implementing an appropriate level of flexibility. In addition, a thread and the like are prevented from coming loose out of a cut cross-section of the base fabric layer 10 even though the base fabric layer 10 is cut out. Further, the coating effect of the thin film layer on the patterns of the base fabric layer is implemented, so that the peeling off and the like of the patterns can be prevented and products can be upgraded by highlighting the beauty of design.

Herein, the ‘composite fabric sheet for ornamentation’ refers to a base fabric sheet on which a thin film layer, a hot melt film layer, and the like are laminated so as to be attached to products such as shoes, bags, wallets, or various pouches as well as various household appliances without sewing to impart an ornamental effect to the products.

Meanwhile, the base fabric layer 10 can apply various materials that can be bonded by means of the hot melt film layers 10 a and 10 b without sewing, but preferably apply a material formed with through-holes H in view of the above-mentioned objects and the effects of the present invention.

Thus, in the present invention, among various materials that can be applied to the base fabric layer 10, an embodiment of a mesh material formed with the through-holes H will be described below.

In the meantime, the thin film layer 20, the first hot melt film layer 10 a, and the second hot melt film layer 10 b may apply various synthetic resins such as polyester, polyethylene, polyacryl and the like, but preferably use thermoplastic polyurethane (TPU) in view of the above-mentioned objects and the effects of the present invention.

The thin film layer 20, the first hot melt film layer 10 a, and the second hot melt film layer 10 b are different from each other in thickness, hardness, and melting point.

More specifically, the thin film layer 20 has a hardness and a melting point that are higher than those of the first hot melt film layer 10 a and the second hot melt film layer 10 b. For example, when the first hot melt film layer 10 a and the second hot melt film layer 10 b have a melting point of 110° C. and a hardness of 75 A, the thin film layer 20 is used which has a melting point of 150° C. and a hardness of 85 A. In addition, when the first hot melt film layer 10 a and the second hot melt film layer 10 b have a melting point of 115° C. and a hardness of 80 A, the thin film layer 20 is used which has a melting point of 155° C. and a hardness of 90 A. Also, when the first hot melt film layer 10 a and the second hot melt film layer 10 b have a melting point of 120° C. and a hardness of 85 A, the thin film layer 20 is used which has a melting point of 160° C. and a hardness of 95 A.

Meanwhile, in case of the TPU film, since the melting point and the hardness can be set variously in the manufacture process thereof, the melting point and the hardness of the thin film layer 20, the first hot melt film layer 10 a, and the second hot melt film layer 10 b are merely illustrative embodiments and the present invention is not limited thereto. That is, in the present invent, the melting point and the hardness can be set variously on the assumption that the thin film layer 20 has a melting point and a hardness that are higher than those of the first hot melt film layer 10 a and the second hot melt film layer 10 b.

Further, in case of the thickness, it is preferable that the thin film layer 20 has a thickness of 200-300 μm, the first hot melt film layer 10 a has a thickness of 30-50 μm, and the second hot melt film layer 10 b has a thickness of 200-300 μm.

In this case, if the thin film layer 20, the first hot melt film layer 10 a, and the second hot melt film layer 10 b is out of the above-mentioned thickness range, there is a risk that an appropriate level of flexibility will not be implemented or an adhesive force will not be sufficient.

In other words, the range of the thicknesses of the thin film layer 20, the first hot melt film layer 10 a, and the second hot melt film layer 10 b is an optimum range derived in order to accomplish the above-mentioned objects (i.e., implementation of an appropriate level of flexibility and improvement of the adhesive force), and the critical meaning of the above range is proven by an experiment below.

Hereinafter, the present invention will be described in detail in connection with examples below, and the invention is not limited to the following examples.

1. Manufacture of a Composite Fabric Sheet for Ornamentation

EXAMPLE 1

A first hot melt film layer was formed between a base fabric layer made of a mesh material and a thin film layer made of TPU, and a second hot melt film layer was formed on the underside of the base fabric layer. Thereafter, the resulting layer structure was pressed at a temperature of 140° C. under a pressure of 50 kg/cm² for 25 seconds using a heat press to thereby manufacture a composite fabric sheet for ornamentation.

In this case, the thickness of the thin film layer was set to be 200 μm, the thickness of the first hot melt film layer was set to be 30 μm, and the thickness of the second hot melt film layer was set to be 150 μm.

EXAMPLE 2

A first hot melt film layer was formed between a base fabric layer made of a mesh material and a thin film layer made of TPU, and a second hot melt film layer was formed on the underside of the base fabric layer. Thereafter, the resulting layer structure was pressed at a temperature of 140° C. under a pressure of 50 kg/cm² for 25 seconds using a heat press to thereby manufacture a composite fabric sheet for ornamentation.

In this case, the thickness of the thin film layer was set to be 200 μm, the thickness of the first hot melt film layer was set to be 50 μm, and the thickness of the second hot melt film layer was set to be 150 μm.

EXAMPLE 3

A first hot melt film layer was formed between a base fabric layer made of a mesh material and a thin film layer made of TPU, and a second hot melt film layer was formed on the underside of the base fabric layer. Thereafter, the resulting layer structure was pressed at a temperature of 140° C. under a pressure of 50 kg/cm² for 25 seconds using a heat press to thereby manufacture a composite fabric sheet for ornamentation.

In this case, the thickness of the thin film layer was set to be 300 μm, the thickness of the first hot melt film layer was set to be 30 μm, and the thickness of the second hot melt film layer was set to be 200 μm.

EXAMPLE 4

A first hot melt film layer was formed between a base fabric layer made of a mesh material and a thin film layer made of TPU, and a second hot melt film layer was formed on the underside of the base fabric layer. Thereafter, the resulting layer structure was pressed at a temperature of 140° C. under a pressure of 50 kg/cm² for 25 seconds using a heat press to thereby manufacture a composite fabric sheet for ornamentation.

In this case, the thickness of the thin film layer was set to be 200 μm, the thickness of the first hot melt film layer was set to be 50 μm, and the thickness of the second hot melt film layer was set to be 300 μm.

COMPARATIVE EXAMPLE 1

A thin film layer was formed on the top surface of a base fabric layer made of a mesh material and a hot melt film layer was formed on the underside of the base fabric layer. Thereafter, the resulting layer structure was pressed at a temperature of 140° C. under a pressure of 50 kg/cm² for 25 seconds using a heat press to thereby manufacture a composite fabric sheet for ornamentation.

In this case, the thickness of the thin film layer was set to be 200 μm, and the thickness of the hot melt film layer was set to be 200 μm.

COMPARATIVE EXAMPLE 2

A thin film layer was formed on the top surface of a base fabric layer made of a mesh material and a hot melt film layer was formed on the underside of the base fabric layer. Thereafter, the resulting layer structure was pressed at a temperature of 140° C. under a pressure of 50 kg/cm² for 25 seconds using a heat press to thereby manufacture a composite fabric sheet for ornamentation.

In this case, the thickness of the thin film layer was set to be 200 μm, and the thickness of the hot melt film layer was set to be 200 μm. As described above, Examples 1 to 4 show that the hot melt film layers are formed both on the top surface and the underside of the base fabric layer, and the thicknesses thereof were set to be different from each other. On the other hand, Comparative Examples 1 and 2 show that the hot melt film layer was formed only on the underside of the base fabric layer, and the thickness thereof were set to be different from each other.

2. Analysis of Manufacture of a Composite Fabric Sheet for Ornamentation

The flexibility and adhesive property of the composite fabric sheets for ornamentation manufactured in the above Examples 1 to 4 and Comparative Examples 1 and 2 was tested using a flexibility tester and an adhesive property tester. A test result of the flexibility was shown in Table 1 below and FIG. 4, respectively, and a test result of the adhesive property was shown in Table 2 below and FIG. 5, respectively.

TABLE 1 Classification Cycle Results Example 1 50,000 Failed Example 2 50,000 Failed Example 3 100,000 Passed Example 4 100,000 Passed Comparative 10,000 Failed Example 1 Comparative 20,000 Failed Example 2 If there is a crack in a relevant cycle, it is evaluated as “Failed”. If there is no crack in a relevant cycle, it is evaluated as “Passed”.

 2 Classification direction value (kg/cm) Example 1 A 1.6, 1.5, 1.4, 1.5, 1.3 B 2.3, 2.0, 2.2, 2.2, 2.2 Example 2 A 2.1, 2.1, 1.4, 1.6, 2.2 B 2.4, 2.9, 3.2, 3.1, 3.3 Example 3 A 4.2, 4.9, 3.4, 3.9, 3.2 B 5.4, 6.5, 5.1, 6.0, 5.1 Example 4 A 5.6, 5.9, 4.4, 4.9, 6.5 B 6.5, 6.0, 6.7, 6.3, 5.6 Comparative Example 1 A 2.0, 2.3, 1.8, 1.9, 2.0 B 2.4, 2.6, 3.1, 1.6, 2.4 Comparative Example 2 A 3.5, 5.2, 3.8, 3.3, 4.7 B 6.7, 6.7, 6.1, 7.2, 5.0

Further, it can be seen from Table 2 and FIG. 5 that in case of Comparative Example 1, Example 1, and Example 2, the manufactured composite fabric sheets for ornamentation was easily peeled off from an adherend substrate whereas in case of Comparative Example 2, Example 3, and Example 4, the manufactured composite fabric sheets for ornamentation was excellent in the adhesive property to such an extent that the adherend substrate is torn out.

That is, it can be seen that in case of Example 3 and Example 4, the values are optimum ranges that can realize an excellent adhesive force while maintaining an appropriate level of flexibility.

As described above, while the composite fabric sheet for ornamentation according to the present invention has been described and illustrated in connection with specific exemplary embodiments with reference to the accompanying drawings, it will be readily appreciated by those skilled in the art that various modifications and changes can be made to the present invention within the technical spirit and scope of the present invention defined in the claims.

BEST MODE

The present invention is directed to a composite fabric sheet for ornamentation, which includes a thin film layer formed on the top surface of a base fabric layer, wherein the composite fabric sheet includes: a first hot melt film layer formed between the base fabric layer and the thin film layer; and a second hot melt film layer formed on the underside of the base fabric layer.

Preferably, the base fabric layer may be composed of a mesh material.

Further, preferably, the thin film layer may have a thickness of 200-300 μm, the first hot melt film layer may have a thickness of 30-50 μm, and the second hot melt film layer may have a thickness of 200-300 μm.

INDUSTRIAL APPLICABILITY

According to the present invention, the hot melt film layers are formed on both the top surface and the underside of a base fabric layer in such a manner that a first hot melt film layer is formed between the base fabric layer and a thin film layer and a second hot melt film layer is further formed on the base fabric layer and an adherend substrate so as to allow the first hot melt film layer and the second hot melt film layer to be fused together by means of through-holes of the base fabric layer, thereby preventing shrinkage even at a high temperature of more than 250° C., and implementing an appropriate level of flexibility while improving the adhesive force of either the adherend substrate and the base fabric layer, or the base fabric layer and the thin film layer.

In addition, the first hot melt film layer and the second hot melt film layer are fused together by means of the through-holes of the base fabric layer, so that a thread and the like is prevented from coming loose out of a cut cross-section of the base fabric layer even though the base fabric layer is cut out. Besides, the coating effect of the thin film layer on the patterns of the base fabric layer is implemented, so that the peeling off and the like of the patterns can be prevented and products can be upgraded by highlighting the beauty of design. Therefore, the present invention is expected to be utilized in a wide range of industrial fields. 

1. A composite fabric sheet for ornamentation, which comprises a thin film layer formed on the top surface of a base fabric layer, the composite fabric sheet comprising: a first hot melt film layer formed between the base fabric layer and the thin film layer; and a second hot melt film layer formed on the underside of the base fabric layer.
 2. The composite fabric sheet for ornamentation according to claim 1, wherein the base fabric layer is composed of a mesh material.
 3. The composite fabric sheet for ornamentation according to claim 1, wherein the thin film layer has a thickness of 200-300 μm, the first hot melt film layer has a thickness of 30-50 μm, and the second hot melt film layer has a thickness of 200-300 μm. 